Window sill flashing

ABSTRACT

The present invention is directed towards a window sill flashing comprising a base having a substantially rectangular shape. A front flange projects perpendicularly downward from a front edge of the base and at least one side flange extends vertically from a side edge of the base. The side flange includes a front surface. The window sill flashing is made from a rigid homopolymer vinyl film.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/487,343, filed Jul. 15, 2003, the entire contents of which are hereinincorporated by reference.

TECHNICAL FIELD

The present invention generally relates to building materials and moreparticularly relates to window sill flashing for a window frame toprevent the ingress of water.

BACKGROUND OF THE INVENTION

Typical wall construction techniques include forming a rough openingfrom framing members such that a window opening is formed. The bottomportion of the window opening (called the sill) is susceptible torotting if water is not prevented from penetrating from around thewindow perimeter. Additionally, adjacent ceilings, plastered walls, andthe like are susceptible to damage if rain-water infiltrates under thewindow sill.

Many systems are used to solve the problem of water intrusion. Onemethod includes providing a means to collect and control the water thatdoes infiltrate the window perimeter. Alternatively, surface sealingagents, such as caulk, expanding foam, and the like are used as fillingagents to fill openings between the periphery of the window and theadjacent, wall surfaces. However, over time, the filling agents have atendency to dry, crack and shrink, thereby exposing gaps which provide apassageway for water to infiltrate the window perimeter.

SUMMARY OF THE INVENTION

The present invention is directed towards a window sill flashingcomprising a base having a substantially rectangular shape. A frontflange projects perpendicularly downward from a front edge of the baseand at least one side flange extends vertically from a side edge of thebase. The side flange includes a front surface. The window sill flashingis made from a vacuum formed, rigid homopolymer vinyl film.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a wall having a window opening and aflashing according to an embodiment of the present invention.

FIG. 2 is an isometric view of a flashing and window assembly accordingto an embodiment of the present invention.

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2.

FIG. 4 is an isometric view of the flashing and window assemblyaccording to an alternate embodiment of the present invention.

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4.

FIG. 6 is a isometric view of the flashing according to yet anotheralternate embodiment of the present invention.

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 6.

FIG. 8 is an isometric view of the flashing according to still yetanother alternate embodiment of the present invention.

FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 8.

FIG. 10 is a perspective view of a wall having a window opening coveredwith housewrap.

FIG. 11 is a perspective view of a wall having a window opening with thehousewrap folded to the proper positions for window installation.

FIG. 12 is a perspective view of a wall having a window opening with afirst portion of the flashing of the present invention installed.

FIG. 13 is a perspective view of a wall having a window opening with asecond portion of the flashing installed.

FIG. 14 is a perspective view of a wall having a window opening with twoflashing portions taped according to an embodiment of the presentinvention.

DETAILED DESCRIPTION

Referring to FIG. 1, a window sill flashing (hereinafter referred to as“flashing”) 10 is generally shown according to an embodiment of thepresent invention. The flashing 10 is formed to fit within and snuglyconform to a bottom portion 12 of a window opening 14 of a wall 15.Window opening 14 has a width W and is adapted to accept a windowassembly 13. As illustrated, the face portion (or flange) 22 of flashing10 is generally U-shaped and constructed as one piece. The flashing 10comprises a base 16, a first side flange 18 integrally formed with base16 at one end, a second side flange 20 integrally formed with base 16 atan opposite end, and a front flange 22 integrally formed with base 16.Preferably base 16, side flanges 18, 20 and front flange 22 are allvacuum formed from, a common sheet. Front (U-shaped) flange 22 extendsperpendicularly downward from an edge of base 16. First side flange 18includes a front surface 18 a and second side flange 20 includes a frontsurface 20 a. The flashing 10 is glued, calked, taped, or otherwisepermanently secured within window opening 14. It is contemplated thatflashing 10 of FIG. 1 is formed in various standard size lengths andwidths to accommodate various standard window openings 14 and wallthicknesses.

FIGS. 2 and 3 illustrate a first alternative embodiment of the flashingof FIG. 1, wherein like features are indicated by the same referencenumber. Flashing 10 a is fabricated as two separate portions 10 a′ and10 a″. Portions 10 a′ and 10 a″ form the left and right side of flashing10. Alternatively, flashing 10 a is fabricated as a one piece memberwith a length (prior to cutting) that spans beyond the width W of windowopening 14. Prior to installation of flashing 10 a into window opening14, flashing 10 a is cut, resulting in portions of flashings 10 a′ and10 a″. It can be appreciated that flashing 10 a may be cut at any pointalong its length, so long as flashings 10 a′ and 10 a″ fit within windowopening 14. Thereafter, portions 10 a′ and 10 a″ are placed so that theypartially overlap one another in a region 24 producing flashing 10 ahaving length L that is generally equal to the width W of window opening14. FIG. 3 is a cross-sectional view of the overlap region 24 ofportions 10 a′ and 10 a″. One advantage of flashing 10 a is thatflashing 10 a may be cut to size in the field to accommodate any width Wof window opening 14.

FIGS. 4 and 5 illustrate a further alternate embodiment of the flashingof the present invention. Flashing 10 b is similar to flashing 10 andflashing 10 a, except portions of flashing 10 b′ and 10 b″ do notoverlap at region 24, Instead, portions 10 b′ and 10 b″ are separated bya gap 26. As illustrated, gap 26 is narrow relative to the width W ofwindow opening 14. However, it can be appreciated that gap 26 may be anydesired length. For instance, gap 26 may expose a substantial portion ofwidth W of window opening 14. Further, gap 26 may be optionally coveredwith a sill flashing cap 28.

FIGS. 6 and 7 illustrate a further embodiment of the flashing of thepresent invention. Flashing 10 c is substantially similar to flashing 10a; however, flashing 10 c includes a rear, vertical rising wall 30 tofurther impede the ingress of water. Rear, vertical rising wall 30 islocated along an edge of base 16, opposite of front flange 22 andextends perpendicularly upward from base 16.

FIGS. 8 and 9 illustrate yet another embodiment of the flashing of thepresent invention. Flashing 10 d is substantially similar to flashing 10b; however, flashing 10 b includes rear, vertical rising wall 30.

FIGS. 10-14 illustrate the steps for installing flashing 10 withinwindow opening 14. Initially, the window opening 14 is covered withhousewrap 32. Mousewrap 32 is then cut along perforated lines 34.Perforated lines 34 divide housewrap 32 into upper section 32 a, lowersection 32 b, left side 32 c and right side 32 d. The lower section 32 band left and right sides 32 c, 32 d of housewrap 32 are folded inwardly,towards the interior surface of wall 15. Upper section 32 a is rolled uptowards the exterior of wall 15, in the direction of arrows A (see FIG.11). Thereafter, flashing 10 or portions of flashing 10 a″, 10 b″, 10 c″or 10 d″ are placed on top of bottom portion 12 of window opening 14(see FIG. 12). FIG. 13 illustrate flashing portions 10 a′, 10 b′, 10 c′,or 10 d′ being placed along bottom portion 12. Finally, flashing 10 issecured to bottom portion 12. FIG. 14 illustrates flashing 10 beingsecured to bottom portion 12 with adhesive tape 36. Adhesive tape 36 isalso used to seal the seam created by the overlap 24 between right andleft portions of the flashing 10. Where there is no overlap 24, adhesivetape 36 may be used to cover the bottom portion 12 of window opening 14.Thereafter, a window 13 is installed within window opening 14.

The flashing 10 of the present invention is preferably manufactured fromsheets of thermoforming film, such as a rigid homopolymer vinyl film, orpolyvinyl chloride (PVC), or the like. The preferable materialproperties for flashing 10 are listed in the table below:

Property Units Value Gauge Range Mils 7.5-35 Gauge Tolerance % ±5Specific Gravity — 1.33 Material Yield (Nominal) in.²/lb. 2770 (7.5mil)  2080 (10.0 mil) 1390 (15.0 mil) 1040 (20.0 mil) Tensile Strength(Yield) lb./in.² 6600 Elongation (Break) % 180 Tensile Impact Strengthft-lb./in.² 275 Cold Break Temperature ° C. −30 Heat DeflectionTemperature at 264 psi ° F. 162 Gloss % 115It can be appreciated that the flashing 10 may be covered with asilicone coating for ease of manufacturing and separation of theflashing 10 and for ease in installation of window assembly 13.

Flashing 10 is preferably fabricated using vacuum forming techniques.Vacuum forming flashing 10 from thin gage material allows the first andsecond side flanges 18, 20 to be substantially perpendicular to base 16.The material properties, including the material thickness, providesflexibility to flashing 10, thus allowing the vacuum forming dies toseparate from the flashing 10 once the vacuum forming process iscompleted. Additionally, vacuum forming flashing 10 allows the materialto have a minimum thickness (as thin as 7.5 mm). Therefore, whenportions of flashing 10 overlap, the resultant gap under the flashing 10is minimal and does not allow water intrusions.

Due to the geometry and thinness of flashing 10, flashing 10 cannot hemanufactured using an injection molding process. if flashing 10 were tobe manufactured by injection molding, the minimum thickness feasible forflashing 10 is 40 mm, significantly higher than the practical thicknessof flashing 10 formed by the vacuum forming process. Moreover, tomaintain the perpendicularity of surfaces 16, 18, 20 and 22 over thedepth of base 16, flashing 10 would require ribs, or support struts, tobe molded into base 16. These ribs would detract from the functionalityof flashing 10. Furthermore, it would be necessary to include portsalong base 16 to ensure that sufficient material flows across and coversthe entire base 16. These ports would give rise to dimples, or otherimperfections in the surface of base 16. The imperfections could creategaps or openings along the window sill, thereby comprising the waterimpermeability of flashing 10. Even with the use of ports along base 16,obtaining complete flow coverage of injected material is problematicbecause the preferred depth of base 1 is in the range of 1 inches to 3¼inches.

The embodiments disclosed herein have been discussed for the purpose offamiliarizing the reader with novel aspects of the invention. Althoughpreferred embodiments of the invention have been shown and described,many changes, modifications and substitutions may be made by one havingordinary skill in the art without necessarily departing from the spiritand scope of the invention as described in the following claims.

1-14. (canceled)
 15. A window sill flashing, comprising: a base having asubstantially rectangular shape; a front flange projectingperpendicularly downward from a front edge of the base; at least oneside flange extending vertically from a side edge of the base, the atleast one side flange including a front surface; and a front flange thatextends perpendicularly downward from the front edge of the base andintegrally adjoins the front surface; wherein said window sill flashingis made from a sheet of thermoforming film; wherein each of the flanges,the base portion and the front surface of the window sill flashingdefine a continuous shaped structure; and wherein the flashing isadapted to be cut to size in the field to accommodate any width ofwindow opening.
 16. The window sill flashing of claim 15, wherein a rearwall extends perpendicularly upward along a rear edge of the base andwherein each of the flanges, the base portion, the rear wall and thefront surface of the window sill flashing define a continuous shapedstructure.
 17. The window sill flashing of claim 15, wherein the onepiece plastic member comprise a thin gage material having a thickness inthe range of 7.5-35 mils.
 18. The window sill flashing of claim 16,wherein the one piece plastic member comprise a thin gage materialhaving a thickness in the range of 7.5-35 mils.
 19. A method of forminga window frame assembly for a building, the method including the stepsof: forming an opening in a wall for receiving a window assembly, theopening being defined to include left and right opposing bottom cornerslocated at opposite sides of the opening; providing a first one piecesill flashing that includes: i. a base having a substantiallyrectangular shape; ii. a front flange projecting perpendicularlydownward from a front edge of the base; iii. at least one side flangeextending vertically from a side edge of he base, the at least one sideflange including a front surface; iv. a front flange that extendsperpendicularly downward from the front edge of the base and integrallyadjoins the front surface; wherein the first window sill flashing ismade from a common sheet of thermoforming film; providing a second onepiece sill flashing that includes: i. a base having a substantiallyrectangular shape; ii. a front flange projecting perpendicularlydownward from a front edge of the base; iii. at least one side flangeextending vertically from a side edge of he base, the at least one sideflange including a front surface; and iv. a front flange that extendsperpendicularly downward from the front edge of the base and integrallyadjoins the front surface; wherein the second window sill flashing ismade from a common sheet of thermoforming film; wherein the first onepiece sill flashing is configured to fit in the left bottom corner ofthe opening, and the second one piece sill flashing is configured to fitin a right bottom corner of the opening; cutting to size in the field atleast one of the first or second one piece sill flashings; placing thefirst one piece sill flashing in the left bottom corner of the opening;placing the second one piece sill flashing in the right bottom corner ofthe opening; optionally covering any resulting gap between the first onepiece sill flashing and the second one piece sill flashing; wherein eachof the first and second one piece sill flashings is sufficiently thinthat the members cannot be manufactured using an injection moldingprocess.
 20. The method of claim 19, wherein the attaching of the firstone piece sill flashing and the second one piece sill flashing is suchthat they overlap one another.
 21. The method of claim 19, wherein thefirst and the second sill flashings consist of a thin gage materialhaving a thickness in the range of 7.5-35 mils.
 22. The method of claim20, wherein the first and the second sill flashings consist of a thingage material having a thickness in the range of 7.5-35 mils.
 23. Themethod of claim 19, wherein the base has a rear wall that projectsvertically upward from a rear edge of the base.
 24. The method of claim20, wherein the base has a rear wall that extends perpendicularly upwardalong a rear edge of the base.
 25. The method of claim 21, wherein thebase has a rear wall that extends perpendicularly upward along a rearedge of the base.
 26. The method of claim 22, wherein the base has arear wall that extends perpendicularly upward along a rear edge of thebase.
 27. A method of making a window sill flashing, comprising: formingfrom a common sheet of a thermoforming film a thin one piece plasticsill flashing that includes: i. a base having a substantiallyrectangular shape; ii. a front flange projecting perpendicularlydownward from a front edge of the base; iii at least one side flangeextending vertically from a side edge of the base, the at least one sideflange including a front surface; and a front flange that extendsperpendicularly downward from the front edge of the base and integrallyadjoins the front surface.
 28. The method of claim 27, wherein theflashing includes a rear wall that extends perpendicularly upward alonga rear edge of the base.
 29. The method of claim 27, wherein the thinone piece plastic member consists of a thin gage material having athickness in the range of 7.5-35 mils, wherein the flashing is adaptedto be cut to size in the field to accommodate any width of windowopening, and wherein each of the flanges, the base portion and the frontsurface of the window sill flashing define a continuous shapedstructure.
 30. The flashing of claim 28, wherein the thin one piecemolded plastic member consists of a thin gage material having athickness in the range of 7.5-35 mils, wherein the flashing is adaptedto be cut to size in the field to accommodate any width of windowopening, and wherein each of the flanges, the base portion, the frontsurface and the rear wall of the window sill flashing define acontinuous shaped structure.
 31. The method of claim 27, wherein theforming of the flashing includes a step of vacuum forming.
 32. Themethod of claim 28, wherein the forming of the flashing includes a stepof vacuum forming.
 33. The method of claim 29, wherein the forming ofthe flashing includes a step of vacuum forming.
 34. The method of claim30, wherein the forming of the flashing includes a step of vacuumforming.